AWR-Fix: Door Handle Carrier Permanent Fix*

[andrewwynn]

Looks pretty good. The nylon zip ties are pretty strong and actually will probably stretch vs. break but you want to put a shim under to make it tight I think I mentioned bit didn't show where in my photos.



The red arrow shows where to put a shim and the cut off end of the zip tie is the perfect material to use.

Also note where the purole arrow is: the zip tie should be down in the valley against the hinge pin else the hinge will pull apart during each use.

Test the hinge out and see if the zip tie is tight enough. When I used nylon zip tie, I noticed the hinge would pull apart a little bit each use (but would still work ok). Upgrade to the steel remedied that.

I thought I was able to get a nylon zip double wound just not directly over itself which doubles the strength.

The beauty of the metal zip is doubled up allows the strength to put a shim under and provide enough pretension there is absolutely no motion of the hinge pin.

When you test it of the car you should see full motion of the cable. Put some low temp low viscosity grease on the gear teeth and something like silicone/Teflon in the cable.

Put some anti-freeze prevention on the door actuator before reassembly. It's the usual cause of the DHC breaking in the first place (though just age and fatigue failure will do it as well)



Note there purple arrow shows how the zip tie is down on the hinge pin (purple) and not up on the hinge "finger" (blue).